Razors

ABSTRACT

Razor handles are provided for razors having a battery-powered functionality. Methods of manufacturing such handles are also provided. In one implementation, the handle includes a unitary grip portion constructed to receive a razor head at one end thereof, and a battery cover, mounted on the grip portion. The grip portion and the battery cover, when joined, may together define a water-tight unit prior to mounting of the razor head on the grip portion.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.11/998,516, filed on Nov. 30, 2007, currently pending, which is adivisional of U.S. application Ser. No. 11/220,008, filed Sep. 6, 2005now abandoned.

TECHNICAL FIELD

This invention relates to razors, and more particularly to razors forwet shaving that include a battery-powered functionality.

BACKGROUND

Recently, some wet shaving razors have been provided with abattery-powered functionality. For example, the Gillette® M3 Power™razor, sold by The Gillette Company, provides a vibrating function thatis powered by a battery disposed in a chamber within the handle of thedevice. The battery is replaceable by the user, by removing a batterycover. It is desirable for safety and durability reasons that the handleof such a device be water-tight.

SUMMARY

The present invention provides razors having handles that are reliablywater-tight and that can be readily sealed by the user when the batterycover is replaced by the user after changing the battery.

In one aspect, the invention features a razor handle for a razor havinga battery-powered functionality, the handle including a unitary gripportion constructed to receive a razor head at one end thereof, and abattery cover, mounted on the grip portion, the grip portion and thebattery cover, when joined, together defining a water-tight unit priorto mounting of the razor head on the grip portion.

Some implementations may include one or more of the following features.The razor handle may further include a plurality of components thatprovide the battery-powered functionality, and all components of therazor that provide the battery-powered functionality may be disposedwithin the grip portion. The razor handle may further include a razorhead, fixedly mounted on the grip portion. The battery cover may beremovably mounted on the grip portion, or, alternatively, may bepermanently welded to the grip tube. The razor handle may furtherinclude a sealing member, e.g., an elastomeric seal, disposed at aninterface between the battery cover and grip portion to provide awater-tight seal at the interface. The razor handle may further includea subassembly, disposed within the grip portion, including a carrier anda switch or electronic components mounted on the carrier. The carriermay include a portion constructed to receive a battery and provideelectrical communication between the battery and electronic components.The carrier may also include a portion constructed to engage acorresponding portion of the battery cover. The handle may furtherinclude a sleeve, disposed inside the battery-receiving portion of thecarrier and surrounding the battery.

In another aspect, the invention features a razor handle for a razorhaving a battery-powered functionality, the handle including: (a) a gripportion; (b) within the grip portion, components configured to providethe battery-powered functionality; (c) an actuator, mounted on the gripportion and positioned to be depressed by a user of the razor; and (d)an electronic switch, in electrical communication with the components,positioned to be actuated when the actuator is depressed.

Some implementations may include one or more of the following features.The electronic switch may require an actuation force of at least 4 Napplied over about a displacement of about 0.25 mm. The grip portion mayinclude a resilient membrane that is interposed between the actuator andthe electronic switch. The resilient membrane may be configured to exerta restoring force on the actuator after the actuator is depressed andreleased. The actuator may include a button and an underlyingcantilevered member supporting the button. The components may include aprinted circuit board, and the electronic switch may be in communicationwith the printed circuit board to activate circuitry of the printedcircuit board. The actuator may include a button, and an upper surfaceof the button may be substantially flush with an outer surface of thegrip tube. The electronics may be configured to drive a vibratingfunction of the razor.

In some implementations, the razor handle may further include a closingsystem, including a first component within the battery cover, and asecond component secured to the interior wall of the grip portion, thefirst component being configured to move axially within the batterycover during engagement of the battery cover with the grip portion, andbeing biased toward a predetermined axial position. The first and secondcomponents may be configured to engage each other by rotation of thebattery cover relative to the housing. The first component may include aspring element configured to apply an axial force between the gripportion and battery cover when the first and second components areengaged. Engagement of the first and second components may provide anelectrical connection between the first and second components. Thehandle may further include, within the grip tube, a pair of batteryclamp fingers configured to exert a clamping force against the batterywhen the battery is in place in the razor.

The grip tube may include a window, and the razor handle may furtherinclude an indicator, e.g., an LED or other light or display, beneaththe window.

In other aspects, the invention features methods of manufacturing razorhandles. In one such aspect, the invention features a method including:(a) forming a unitary grip tube having a closed end configured toreceive a razor head; (b) inserting a battery and a carrier into an openopposite end of the grip tube, the carrier having electronic componentsmounted thereon; (c) sealing the open end of the grip tube; and (d)testing the electronic functionality of the resulting assembly.

Some implementations of this method may include one or more of thefollowing features. The method may also include mounting, e.g., fixedlymounting, a razor head on the closed end if the testing step results ina determination that the electronics are functional. The sealing stepmay include mounting a removable battery cover on the open end. Mountingthe battery cover on the open end may render the assembly water-tight.The razor head may in some cases be configured to receive a disposablerazor cartridge. In other cases, the razor head and razor cartridge maybe integral, e.g., if the razor is a disposable razor. Forming theunitary grip tube may, for example, include molding a grip tube preformhaving a window opening and welding a window into the opening.

In another aspect, the invention features a method of forming aplurality of razor products having a battery-powered functionality. Themethod includes (i) forming a plurality of substantially identical razorsub-assemblies, each sub-assembly including (a) a unitary grip tubehaving a closed end configured to receive a razor head, and (b) abattery and battery-powered components disposed within the grip tube,the grip tube being sealed in a water-tight manner; and (ii) mounting afirst razor head on the closed ends of a first sub-set of the razorsub-assemblies to form a first product, and mounting a second, differentrazor head on the closed ends of a second sub-set of the razorsub-assemblies to form a second, different product.

The details of one or more embodiments of the invention are set forth inthe accompanying drawings and the description below. Other features,objects, and advantages of the invention will be apparent from thedescription and drawings, and from the claims.

DESCRIPTION OF DRAWINGS

FIG. 1 is a top view of a razor handle according to one embodiment.

FIGS. 1A and 1B are cross sectional views of the razor handle of FIG. 1.

FIG. 2 is a bottom view of the razor handle of FIG. 1.

FIG. 3 is a partially exploded view of the razor handle of FIG. 1.

FIG. 4 is a perspective view of the head tube exploded from the griptube of the razor.

FIG. 5 is a side view of the grip tube.

FIG. 6 is an exploded view of the grip tube showing the componentscontained therein.

FIGS. 7-7C are exploded views illustrating the assembly of thecomponents contained in the grip tube.

FIG. 8 is a perspective view of the grip tube with the LED windowexploded from the tube and the actuator button omitted. FIG. 8A is aperspective view of the grip tube with the LED window welded in placeand the actuator button exploded from the tube. FIGS. 8B-8D are enlargedperspective views of a portion of the grip tube, showing steps inassembly of the actuator button onto the tube.

FIG. 9 is a perspective view of a bayonet assembly used in the razor ofFIG. 1. FIG. 9A is an enlarged detail view of area A in FIG. 9. FIG. 9Bis an enlarged detail view of the bayonet assembly with the male andfemale components engaged and the bayonet and battery springscompressed.

FIG. 10 is a side view of the bayonet assembly shown in FIG. 9, rotated90 degrees with respect to the position of the assembly in FIG. 9.

FIG. 11 is an exploded view of the lower portion of the bayonet assemblyand the battery shell that contains the lower portion.

FIG. 12 is a cross-sectional view of the battery shell.

FIG. 13 is an exploded view of the venting components of the batteryshell.

Like reference symbols in the various drawings indicate like elements.

FIG. 14A shows a razor having a speed control switch.

FIG. 14B shows a razor having a speed control switch and a memory forstorage of preferred speeds.

FIG. 14C shows a razor having an indirect power supply.

FIG. 14D shows a voltage converter for the indirect power supply of FIG.14C.

FIG. 14E shows the signals output by the control logic and theoscillator, and their effect on the capacitor voltage.

FIG. 14F shows another voltage converter for the indirect power supplyof FIG. 14C.

FIG. 14G shows a circuit for supplying power to a load.

FIG. 15A shows a blade-life indicator that counts the number of times amotor has started since blade replacement.

FIG. 15B shows a blade-life indicator that accumulates motor-operatingtime since blade replacement.

FIG. 15C shows a blade-life indicator that counts the number of strokessince blade replacement.

FIG. 15D shows a blade-life indicator that accumulates stroke time sinceblade replacement.

FIG. 16A shows a mechanical lock.

FIG. 16B shows a locking circuit in which a lock signal disarms therazor.

FIG. 17A shows a force-measurement circuit that senses variations incurrent drawn by the motor.

FIG. 17B shows a force-measurement circuit that senses variations inmotor speed.

DETAILED DESCRIPTION Overall Razor Structure

Referring to FIG. 1, a razor handle 10 includes a razor head 12, a griptube 14, and a battery shell 16. The razor head 12 includes a connectingstructure for mounting a replaceable razor cartridge (not shown) on thehandle 10, as is well known in the razor art. The grip tube 14 isconstructed to be held by a user during shaving, and to contain thecomponents of the razor that provide the battery-powered functionalityof the razor, e.g., a printed circuit board and a motor configured tocause vibration. The grip tube is a sealed unit to which the head 12 isfixedly attached, allowing modular manufacturing and providing otheradvantages which will be discussed below. Referring to FIG. 3, thebattery shell 16 is removably attached to the grip tube 14, so that theuser may remove the battery shell to replace the battery 18. Theinterface between the battery shell and grip tube is sealed, e.g., by anO-ring 20, providing a water-tight assembly to protect the battery andelectronics within the razor. The O-ring 20 is generally mounted ingroove 21 (FIG. 5) on the grip tube, e.g., by an interference fit.Referring again to FIG. 1, the grip tube 14 includes an actuator button22 that may be pressed by the user to actuate the battery-poweredfunctionality of the razor via an electronic switch 29 (FIG. 7A). Thegrip tube also includes a transparent window 24 to allow the user toview a light 31 or display or other visual indicator (FIG. 7A), e.g., anLED or LCD, that provides a visual indication to the user of batterystatus and/or other information. The light 31 shines through an opening45 (FIG. 8) provided in the grip tube beneath the transparent window.These and other features of the razor handle will be described infurther detail below.

Modular Grip Tube Structure

As discussed above, the grip tube 14 (shown in detail in FIGS. 4 and 5)is a modular assembly, to which the razor head 12 is fixedly attached.The modularity of the grip tube advantageously allows a single type ofgrip tube to be manufactured for use with various different razor headstyles. This in turn simplifies manufacturing of “families” of productswith different heads but the same battery-powered functionality. Thegrip tube is water-tight except for the opening 25 at the end to whichthe battery shell is attached, and is preferably a single, unitary part.Thus, the only seal that is required to ensure water-tightness of therazor handle 10 is the seal between the grip tube and the battery shell,provided by O-ring 20 (FIG. 3). This single-seal configuration minimizesthe risk of water or moisture infiltrating the razor handle and damagingthe electronics.

As shown in FIG. 6, the grip tube 14 contains a subassembly 26 (alsoshown in FIG. 7C) which includes a vibration motor 28, a printed circuitboard 30, an electronic switch 29 and the light 31 mounted on theprinted circuit board, and the positive contact 32 for providing batterypower to the electronics. These components are assembled within acarrier 34 which also includes battery clamp fingers 36 and a malebayonet portion 38, the functions of which will be discussed in theBattery Clamp and Battery Shell Attachment sections below. The assemblyof all the functional electronic components of the razor onto thecarrier 34 allows the battery-powered functionality to be pre-tested sothat failures can be detected early, minimizing costly scrapping ofcompleted razors. Subassembly 26 also includes an insulation sleeve 40and mounting tape 42, the function of which will be discussed in theBattery Clamp section below.

The subassembly 26 is assembled as shown in FIGS. 7-7C. First, thepositive contact 32 is assembled onto a PCB carrier 44, which is thenmounted on carrier 34 (FIG. 7). Next, the printed circuit board 30 isplaced in the PCB carrier 44 (FIG. 7A), and the vibration motor 28 ismounted on the carrier 34 (FIG. 7B) with lead wires 46 being solderedonto the printed circuit board to complete the subassembly 26 (FIG. 7C).The subassembly may then be tested prior to assembly into the grip tube.

The subassembly 26 is assembled into the grip tube so that it will bepermanently retained therein. For example, the subassembly 26 mayinclude protrusions or arms that engage corresponding recesses in theinner wall of the grip tube in an interference fit.

The grip tube also includes an actuator button 22. The rigid actuatorbutton is mounted on a receiving member 48 (FIG. 8) that includes thewindow 24, discussed above. The receiving member 48 includes acantilevered beam 50 that carries an actuator member 52. Actuator member52 transmits force that is applied to the button 22 to an underlyingresilient membrane 54 (FIG. 8). Membrane 54 may be, for example, anelastomeric material that is molded onto the grip tube to form not onlythe membrane but also an elastomeric gripping portion. The cantileveredbeam, acting in concert with the membrane, provides a restoring force toreturn the button 22 to its normal position after it is depressed by auser. When the button is depressed, the actuator member 52 contacts theunderlying electronic switch 29, which activates the circuitry of thePCB 30. Activation may be by a “push and release” on/off action or otherdesired action, e.g., push on/push off. The electronic switch 29 makesan audible “click” when actuated, giving the user feedback that thedevice has been correctly turned on. The switch is preferably configuredto require a relatively high actuation force applied over a smalldistance (e.g., at least 4 N applied over about an 0.25 mmdisplacement). This switch arrangement, combined with the recessed, lowprofile geometry of button 22, tends to prevent the razor from beingaccidentally turned on during travel, or inadvertently turned off duringshaving. Moreover, the structure of the switch/membrane/actuator memberassembly provides the user with good tactile feedback. The actuatormember 52 also holds the button 22 in place, the aperture 55 in thecenter of the actuator member 52 receiving a protrusion 56 on theunderside of the button 22 (FIG. 8B).

Adjacent to the button 22 is the transparent window 24, through whichthe user can observe the indications provided by the underlying light,which are described in detail in the Electronics section below.

Assembly of the window 24 and actuator button onto the grip tube, isillustrated in FIGS. 8-8D. First, the receiving member 48, carrying thewindow 24, is sealingly mounted on the grip tube, e.g., by gluing orultrasonic or heat welding (FIG. 8), to form the unitary water-tightpart discussed above. Next, the button 22 is slid into place and gently(preferably with less than 10 N force) pushed down into the opening inthe receiving member, causing the protrusion 56 to engage the aperture55 (FIGS. 8A-8C).

Battery Shell Attachment

As discussed above, the battery shell 16 is removably attached to thegrip tube 14, allowing removal and replacement of the battery. The twoparts of the handle are connected, and electrical contact is establishedbetween the negative terminal of the battery and the electroniccomponents, by a bayonet connection. The grip tube carries the maleportion of the bayonet connection, while the battery shell carries thefemale portion. The assembled bayonet connection, with the grip tube andbattery shell omitted for clarity, is shown in FIGS. 9, 9A and 10.

The male bayonet portion 38 of the carrier 34, discussed above, providesthe male portion of the bayonet connection. Male bayonet portion 38carries a pair of protrusions 60. These protrusions are constructed tobe received and retained in corresponding slots 62 in a female bayonetcomponent 64, carried by the battery shell. Each slot 62 includes alead-in having angled walls 66, 68 (FIG. 9A), to guide each protrusioninto the corresponding slot as the battery shell is rotated relative tothe grip tube. A detent area 65 (FIG. 9A) is provided at the end of eachslot 62. The engagement of the protrusions in the detent areas 65 (FIG.9B) provides a secure, twist-on mechanical connection of the batteryshell to the grip tube.

The carrier 34 and the female bayonet component 64 are both made ofmetal, and thus engagement of the protrusions with the slots alsoprovides electrical contact between the carrier and the female bayonetcomponent. The carrier is in turn in electrical contact with circuitryof the device, and the negative terminal of the battery is in contactwith a battery spring 70 (FIG. 9A) that is in electrical communicationwith the female bayonet component, and thus contact of the springmembers and electrical part ultimately results in contact between thebattery and the circuitry of the device.

As shown in FIG. 12, the battery spring 70 is mounted on a spring holder72, which is in turn mounted fixedly to the inner wall of the batteryshell 16. The female bayonet component 64 is free to slide axially backand forth within the battery shell 16. In its rest position, the femalebayonet component is biased to the base of the battery shell by abayonet spring 74. The bayonet spring 74 is also mounted on the springholder 72 and thus its upper end is fixedly mounted with respect to theinner wall of the battery shell. When the battery shell is twisted ontothe grip tube, the engagement of the protrusions on the male bayonetcomponent with the angled slots on the female bayonet component drawsthe female bayonet component forward, compressing the bayonet spring 74.The biasing force of the bayonet spring then causes the female bayonetcomponent to pull the male bayonet component and thus the grip tubetoward the battery shell. As a result, any gap between the two parts ofthe handle is closed by the spring force and the O-ring is compressed toprovide a water-tight sealing engagement. When engagement is completeand the protrusions 60 are received into the corresponding V-shapeddetent areas 65 of the female bayonet slots 62 (FIG. 9B). This isperceived by the user as a clear and audible click, providing a clearindication that the battery shell has been correctly engaged. This clickis the result of the action of the bayonet spring causing theprotrusions to slide quickly into the V-shaped detent areas 65.

This resilient engagement of the battery shell with the grip tubecompensates for non-linear seam lines between the battery shell and griptube and other geometry issues such as tolerances. The force applied bythe bayonet spring also provides solid and reliable electrical contactbetween the male and female bayonet components.

The spring-loaded female bayonet component also limits the force actingon the male and female bayonet components when the battery shell isattached and removed. If, after the grip tube and battery shell contacteach other, the user continues to rotate the battery shell, the femalebayonet component can move forward slightly within the battery shell,reducing the force applied by the protrusions of the male bayonetcomponent. Thus, the force is kept relatively constant, and within apredetermined range. This feature can prevent damage to parts due torough handling by the user or large part or assembly tolerances.

To accomplish the resilient engagement described above, it is generallyimportant that the spring force of the bayonet spring be greater thanthat of the battery spring. Generally, the preferred relative forces ofthe two springs may be calculated as follows:

1. Design the battery spring such that the contact force Fbatmin appliedby the spring is sufficient for a minimum battery length.

2. Calculate the battery spring force Fbatmax that would be required fora maximum battery length.

3. Calculate the maximum force Fpmax that would be required to push thebattery shell against the grip tube to overcome the friction of theo-ring.

4. Determine the minimum closing force Fclmin with which the batteryshell should be pressed against the grip tube in the closed condition.

5. Calculate the force applied by the bayonet spring according toFbayonet=Fbatmax+Fpmax+Fclmin.

As an example, in some implementations Fbatmax=4 N, Fpmax=2 N, andFclmin=2 N, and thus Fbayonet=8 N.

Battery Clamp

As discussed above, carrier 34 includes a pair of battery clamp fingers36 (FIGS. 6, 10). These fingers act as two springs which exert a smallclamping force against the battery 18 (FIG. 3). This clamping force issufficiently strong so as to prevent the battery from rattling againstthe inner wall of the grip tube or against other parts, reducing thenoise generated by the razor during use. Preferably, the clamping forceis also sufficiently strong so as to keep the battery from falling outwhen the battery shell is removed and the grip tube is inverted. On theother hand, the clamping force should be weak enough so that the usercan easily remove and replace the battery. The male bayonet component 38includes open areas 80 (FIG. 4) through which the battery can be graspedby the user for removal.

The dimensions of the spring fingers and their spring force aregenerally adjusted to allow the spring fingers to hold the weight of theminimum size battery discussed above, to prevent it from falling outwhen the razor is held vertical, while also allowing the maximum sizebattery to be easily removed from the grip tube. To satisfy theseconstraints, it some implementations it is preferred that, with acoefficient of friction between the battery and foil of about 0.15-0.30,the spring force for one finger be about 0.5 N when a minimum sizebattery (e.g., having a diameter of 9.5 mm) is inserted and less thanabout 2.5 N when a maximum size battery (e.g., having a diameter of 10.5mm) is inserted. In general, the spring fingers will perform the abovefunctions if, when the razor is held with the battery opening pointingdownwards, the minimum size battery will not fall out and the maximumsize battery can be taken out easily.

Referring to FIGS. 6 and 7C, a thin insulation sleeve 40, e.g., ofplastic foil, further damps vibration noise and provides safety againsta short circuit if the battery surface is damaged. As shown in FIG. 7C,the sleeve 40 is secured with tape 42 to the battery clamp fingers tohold the sleeve in place when the battery is removed and replaced. Asuitable material for the insulation sleeve is polyethyleneterephthalate (PET) film having a thickness of about 0.06 mm.

Venting Battery Compartment

Under certain conditions, hydrogen can accumulate in the interior ofbattery-powered appliances. The hydrogen may be released from thebattery, or may be created by electrolysis outside the battery. Mixingof this hydrogen with ambient oxygen can form an explosive gas, whichcould potentially be ignited by a spark from the motor or switch of thedevice. Thus, any hydrogen should be vented from the razor handle, whilestill maintaining water tightness.

Referring to FIG. 13, a vent hole 90 is provided in the battery shell16. A microporous membrane 92 that is gas-permeable but impermeable toliquids is welded to the battery shell 16 to cover the vent hole 90. Asuitable membrane material is polytetrafluoroethylene (PTFE),commercially available from GORE. A preferred membrane has a thicknessof about 0.2 mm It is generally preferred that the membrane have awater-proofness of at least 70 kPa, and an air permeability of at least12 1/hr/cm² at 100 mbar overpressure.

An advantage of the microporous membrane is that it will vent hydrogenby diffusion due to the difference in partial pressures of hydrogen onthe two sides of the membrane. No increase in total pressure within therazor handle is required for venting to occur.

It is undesirable from an aesthetic standpoint for the user to see thevent hole and membrane. Moreover, if the membrane is exposed there is arisk that the pores of the membrane will become clogged, and/or that themembrane will be damaged or removed. To protect the membrane, a cover 94is attached to the battery shell over the membrane/vent area, e.g., bygluing. So that gas can escape from under the cover 94, an open area isprovided between the inner surface of the cover and the outer surface 98of the battery shell 16. In the implementation shown in the Figures, aplurality of ribs 96 are provided on the battery shell adjacent the venthole 90, creating air channels between the cover and the battery shell.However, if desired other structures can be used to create the ventingspace, for example the cover and/or the grip tube may include adepressed groove that defines a single channel and the ribs may beomitted.

The height and width of the air channels are selected to provide a safedegree of venting. In one example (not shown), there may be one channelon each side of the vent hole, each channel having a height of 0.15 mmand width of 1.1 mm.

Cover 94 may be decorative. For example, the cover may carry a logo orother decoration. The cover 94 may also provide a tactile grippingsurface or other ergonomic features.

Electronics

Variable Speed Control

A powered razor is often used to shave different types of hair atdifferent locations on the body. These hairs have markedly differentcharacteristics. For example, whiskers tend to be thicker than hair onthe legs. These hairs also protrude from the skin at different angles.For example, stubble is predominantly orthogonal to the skin, whereasleg hairs tend to lay flatter.

The ease with which one can shave these hairs depends, in part, on thefrequency at which the cartridge vibrates. Since these hairs havedifferent characteristics, it follows that different vibrationfrequencies may be optimal for different types of hair. It is thereforeuseful to provide a way for the user to control this vibrationfrequency.

As shown in FIG. 14A, the vibration frequency of the shaving cartridgeis controlled by a pulse width modulator 301 having a duty cycle underthe control of control logic 105. As used herein, “duty cycle” means theratio between the temporal extent of a pulse and that of the pausebetween pulses. A low duty cycle is thus characterized by short pulseswith long waits between pulses, whereas a high duty cycle ischaracterized by long pulses with short waits between pulses. Varyingthe duty cycle varies the speed of the motor 306, which in turn governsthe vibration frequency of the shaving cartridge.

The control logic 105 can be implemented in a microcontroller or othermicroprocessor based system. Control logic can also be implemented in anapplication-specific integrated circuit (“ASIC”) or as afield-programmable gate array (“FPGA”).

The motor 306 can be any energy-consuming device that causes movement ofthe shaving cartridge. One implementation of a motor 306 includes aminiature stator and rotor coupled to the shaving cartridge. Anotherimplementation of a motor 306 includes a piezoelectric device coupled tothe shaving cartridge. Or, the motor 306 can be implemented as a devicethat is magnetically coupled to the shaving cartridge with anoscillating magnetic field.

In razors having variable speed control, the control logic 105 receivesan input speed control signal 302 from a speed-control switch 304. Inresponse to the speed control signal 302, the control logic 105 causesthe pulse-width modulator 301 to vary its duty cycle. This, in turn,causes the motor speed to vary. The pulse-width modulator 301 can thusbe viewed as a speed controller.

The speed-control switch 304 can be implemented in a variety of ways.For example, the speed-control switch can move continuously. In thiscase, the user can select from a continuum of speeds. Or, thespeed-control switch 304 can have discrete stops, so that the user canselect from a set of pre-defined motor speeds.

The speed-control switch 304 can take a variety of forms. For example,the switch 304 can be a knob or a slider that moves continuously orbetween discrete steps. The switch 304 can also be a set of buttons,with each one assigned to a different speed.

Or, the switch 304 can be a pair of buttons, with one button beingassigned to increase and the other to decrease the speed. Or, the switch304 can be a single button that one presses to cycle through speeds,either continuously or discretely.

Another type of switch 304 is a spring-loaded trigger. This type ofswitch enables the user to vary the vibration frequency continuouslywhile shaving in the same way that one can continuously vary the speedof a chain saw by squeezing a trigger.

The actuator button 22 can also be pressed into service as a speedcontrol switch 304 by suitably programming the control logic 105. Forexample, one can program the control logic 105 to consider adouble-click or a long press of the actuator button 22 as a command tovary the motor speed.

Among the available speeds is one that is optimized for cleaning therazor. An example of such a speed is the highest possible vibrationfrequency, which is achieved by causing the control logic 105 to drivethe duty cycle as high as possible. Alternatively, the control logic 105can operate in a cleaning mode in which it causes the motor 306 to sweepthrough a range of vibration frequencies. This enables the motor 306 tostimulate different mechanical resonance frequencies associated with theblades, the cartridge, and any contaminating particles, such as shavenwhisker fragments. The cleaning mode can be implemented as a continuoussweep across a frequency range, or as a stepped sweep, in which thecontrol logic 105 causes the motor 306 to step through several discretefrequencies, pausing momentarily at each such frequency.

In some cases, it is useful to enable the razor to remember one or morepreferred vibration frequencies. This is achieved, as shown in FIG. 14B,by providing a memory in communication with the control logic 105. Touse this feature, the user selects a speed and causes transmission of amemory signal, either with a separate control, or by pressing theactuator button 22 according to a pre-defined sequence. The user canthen recall this memorized speed when necessary, again by either using aseparate control or by pressing the actuator button 22 according to apre-defined sequence.

As shown in FIGS. 3A-3B, the razor features an indirect switching systemin which the actuator button 22 controls the motor 306 indirectlythrough control logic 105 that operates the pulse-width modulator 301.Thus, unlike a purely mechanical switching system, in which the state ofthe switch directly stores the state of the motor 306, the indirectswitching system stores the state of the motor 306 in the control logic105.

Since the actuator button 22 no longer needs to mechanically store thestate of the motor 306, the indirect switching system provides greaterflexibility in the choice and placement of the actuator button 22. Forexample, a razor with an indirect switching system, as disclosed herein,can use ergonomic buttons that combine the advantages of clear tactilefeedback and shorter travel. Such buttons, with their shorter travel,are also easier to seal against moisture intrusion.

Another advantage to the indirect switching system is that the controllogic 105 can be programmed to interpret the pattern of actuation and toinfer, on the basis of that pattern, the user's intent. This has alreadybeen discussed above in connection with controlling the speed of themotor 306. However, the control logic 105 can also be programmed todetect and ignore abnormal operation of the actuator button 22. Thus, anunusually long press of the actuator button 22, such as that which mayoccur unintentionally while shaving, will be ignored. This featureprevents the annoyance associated with accidentally turning off themotor 306.

Voltage Controller

The effectiveness of the razor depends in part on the voltage providedby a battery 316. In a conventional motorized wet razor, there exists anoptimum voltage or voltage range. Once the battery voltage is outsidethe optimum voltage range, the effectiveness of the razor iscompromised.

To overcome this difficulty, the razor features an indirect powersupply, shown in FIG. 14C, that separates the voltage of the battery 316from the voltage actually seen by the motor 306. The voltage actuallyseen by the motor 306 is controlled by the control logic 105, whichmonitors the battery voltage and, in response to a measurement ofbattery voltage, controls various devices that ultimately compensate forvariations in battery voltage. This results in an essentially constantvoltage as seen by the motor 306.

The method and system described herein for controlling the voltage seenby a motor 306 is applicable to any energy-consuming load. For thisreason, FIG. 14C refers to a generalized load 306.

In one embodiment, the motor 306 is designed to operate at an operatingvoltage that is less than the nominal battery voltage. As a result, whena new battery 316 is inserted, the battery voltage is too high and mustbe reduced. The extent of the reduction decreases as the battery 316wears down, until finally, no reduction is necessary.

Voltage reduction is readily carried out by providing a voltage monitor312 in electrical communication with the battery 316. The voltagemonitor 312 outputs a measured battery voltage to the control logic 105.In response, the control logic 105 changes the duty cycle of thepulse-width modulator 301 to maintain a constant voltage as seen by themotor 306. For example, if the battery voltage is measured at 1.5 volts,and the motor 306 is designed to operate at one volt, the control logic105 will set the duty cycle ratio to be 75%. This will result in anoutput voltage from the pulse-width modulator 301 that is, on average,consistent with the motor's operating voltage.

In most cases, the duty cycle is a non-linear function of the batteryvoltage. In that case, the control logic 105 is configured either toperform the calculation using the non-linear function, or to use alook-up table to determine the correct duty cycle. Alternatively, thecontrol logic 105 can obtain a voltage measurement from the output ofthe pulse-width modulator 301 and use that measurement to providefeedback control of the output voltage.

In another embodiment, the motor 306 is designed to operate at anoperating voltage that is higher than the nominal battery voltage. Inthat case, the battery voltage is stepped up by increasing amounts asthe battery 316 wears down. This second embodiment features a voltagemonitor 312 as described above, together with a voltage converter 314that is controlled by the control logic 105. A suitable voltageconverter 314 is described in detail below.

A third embodiment combines both of the foregoing embodiments in onedevice. In this case, the control logic 105 begins by reducing theoutput voltage when the measured battery voltage exceeds the motoroperating voltage. Then, when the measured battery voltage falls belowthe motor operating voltage, the control logic 105 fixes the duty cycleand begins controlling the voltage converter 312.

In a conventional powered razor, the motor speed gradually decreases asthe battery 316 wears down. This gradual decrease provides the user withample warning to replace the battery 316. However, in a powered razorwith an indirect power supply, there is no such warning. Once thebattery voltage falls below some lower threshold, the motor speeddecreases abruptly, perhaps even in the middle of a shave.

To prevent this inconvenience, the control logic 105, on the basis ofinformation provided by the voltage monitor 312, provides a low-batterysignal to a low-battery indicator 414. The low-battery indicator 414 canbe a single-state output device, such as an LED, that lights up when thevoltage falls below a threshold, or conversely, that remains lit whenthe voltage is above a threshold and goes out when the voltage fallsbelow that threshold. Or, the low-battery indicator 414 can be amulti-state device, such as a liquid crystal display, that provides agraphical or numerical display indicative of the state of the battery316.

The voltage monitor 312, in conjunction with the control logic 105, canalso be used to disable operation of the razor completely when thebattery voltage falls below a deep-discharge threshold. This featurereduces the likelihood of damage to the razor caused by battery leakagethat may result from deep-discharge of the battery 316.

A suitable voltage converter 312, shown in FIG. 14D, features a switchS1 that controls an oscillator. This switch is coupled to the actuatorbutton 22. A user who presses the actuator button 22 thus turns on theoscillator. The oscillator output is connected to the gate of atransistor T1, which functions as a switch under the control of theoscillator. A battery 316 provides a battery voltage V_(BAT).

When the transistor T1 is in its conducting state, a current flows fromthe battery 316 through an inductor L1, thus storing energy in theinductor L1. When the transistor is in its non-conducting state, thecurrent through the inductor L1 will continue to flow, this time throughthe diode D1. This results in the transfer of charge through the diodeD1 and into the capacitor C1. The use of a diode D1 prevents thecapacitor C1 from discharging to ground through the transistor T1. Theoscillator thus controls the voltage across the capacitor C1 byselectively allowing charge to accumulate into the capacitor C1, therebyraising its voltage.

In the circuit shown in FIG. 14D, the oscillator causes a time-varyingcurrent to exist in the inductor L1. As a result, the oscillator inducesa voltage across the inductor L1. This induced voltage is then added tothe battery voltage, with the resulting sum being available across thecapacitor C1. This results in an output voltage, at the capacitor C1that is greater than the voltage provided by the battery alone.

The capacitor voltage, which is essentially the output voltage of thevoltage converter 312, is connected to both the control logic 105 and tothe pulse-width modulator 301 that ultimately drives the motor 306. Whenthe capacitor voltage reaches a particular threshold, the control logic105 outputs an oscillator control signal “osc_ctr” that is connected tothe oscillator. The control logic 105 uses the oscillator control signalto selectively turn the oscillator on and off, thereby regulating thecapacitor voltage in response to feedback from the capacitor voltageitself. The set point of this feedback control system, i.e. the voltageacross the capacitor C1, is set to be the constant operating voltageseen by the motor 306.

A resistor R1 disposed between the oscillator and ground functions aspart of a decoupling circuit to selectively transfer control of theoscillator from the switch S1 to the control logic 105. Beforeinitialization of the control logic, the port that carries theoscillator control signal (the “oscillator control port”) is set to be ahigh-impedance input port. As a result, it is the switch S1 thatcontrols the operation of the oscillator. The resistor R1 in this caseprevents a short circuit from the oscillator control port to ground.Following initialization, the oscillator control port becomes alow-impedance output port.

Eventually, the user will complete shaving, in which case he may want toturn off the motor 306. With the control logic 105 now controlling theoscillator, there would be no way to turn off the shaver withoutremoving the battery 316. To avoid this difficulty, it is useful toperiodically determine the state of the external switch S1. This isachieved by configuring the control logic 105 to periodically cause theoscillator control port to become a high-impedance input port, so thatthe voltage across the resistor R1 can be sampled.

In certain types of switches, the state of the switch indicates theuser's intent. For example, a switch S1 in the closed position indicatesthat the user wishes to turn on the motor 306, and a switch S1 in anopen position indicates that the user wishes to turn off the motor 306.If the voltage thus sampled indicates that the user has opened theswitch S1, then, when the oscillator control port again becomes alow-impedance output port, the control logic 105 causes the oscillatorcontrol signal to shut down the oscillator, thereby shutting down bothmotor 306. In doing to, the control logic 105 also shuts down its ownpower supply.

In other types of switches, closing of the switch S1 indicates only thatthe user wishes to change the state of the motor from on to off or viceversa. In embodiments that use such switches, the voltage across theresistor R1 changes only briefly when the user actuates the switch S1.As a result, the control logic 105 causes the voltage across theresistor R1 to be sampled frequently enough to ensure capturing theuser's momentary actuation of the switch S1.

FIG. 14E shows the interaction between the oscillator control signal,the oscillator output, and the capacitor voltage. When the capacitorvoltage falls below a lower threshold, the oscillator control signalturns on, thereby turning the oscillator on. This causes more charge toaccumulate in the capacitor C1, which in turn raises the capacitorvoltage. Once the capacitor voltage reaches an upper threshold, theoscillator control signal turns off, thereby turning off the oscillator.With no more charge accumulating in the capacitor C1 from the battery316, the accumulated charge begins to drain away and the capacitorvoltage begins to decrease. It does so until it reaches the lowerthreshold once again, at which point the foregoing cycle repeats itself.

Another embodiment of a voltage converter 312, shown in FIG. 14F isidentical to that described in connection with FIG. 14D with theexception that the diode D1 is replaced by an additional transistor T2having a gate controlled by an RC circuit (R2 and C2). In thisembodiment, when the oscillator is inactive, the voltage between theemitter and the base (V_(BE2)) of the additional transistor T2 is zero.As a result, current flow through the additional transistor T2 is turnedoff. This means that no charge is being provided to the capacitor C1 toreplace charge that is being drained from the capacitor C1. When theoscillator is active, and the oscillator frequency is greater than thecut-off frequency of the RC circuit, then the voltage between theemitter and the base V_(BE2) will be approximately half the batteryvoltage V_(BAT). As a result, the additional transistor T2 functions asa diode to pass current to the capacitor C1, while preventing thecapacitor C1 from discharging to ground.

Another notable feature of the circuit in FIG. 14F is that thepulse-width modulator 301 is supplied with a voltage directly from thebattery 316. As a result, the output voltage of the pulse-widthmodulator 301 can be no higher than the battery voltage. Thus, in FIG.14F, the motor 306 is powered by a step down in voltage, whereas thestepped up voltage, which is the voltage across the capacitor C1, isused to power the control logic 105. However, the circuit shown in FIG.14F can also feature a pulse-width modulator 316 that takes its inputfrom the voltage across the capacitor C1, as shown in FIG. 14D.

FIG. 14G shows a circuit for driving a voltage converter 312 of the typeshown in FIG. 14F in greater detail. The oscillator is shown in greaterdetail, as are the connections associated with the control logic 105.However, the circuit shown in FIG. 14G is otherwise essentiallyidentical to that described in connection with FIG. 14D modified asshown in FIG. 14F.

As described herein, a voltage control system provides a constantoperating voltage to a motor 306. However, a powered razor may includeloads other than a motor. Any or all of these loads may likewise benefitfrom a constant operating voltage as provided by the voltage controlsystem disclosed herein.

One load that may benefit from a constant operating voltage is thecontrol logic 105 itself. Commercially available logic circuits 105, aretypically designed to operate at a voltage that is higher than the 1.5volts available in a conventional battery. Hence, a voltage controlsystem that provides a step up in voltage to the control logic is usefulto avoid the need for additional batteries.

Cartridge Lifetime Detection

In the course of slicing through hundreds of whiskers on a daily basis,the blades of a razor cartridge inevitably grow duller. This dullness isdifficult to detect by visual inspection. As a rule, dull blades areonly detected when it is too late. In too many cases, by the time a userrealizes that a blade is too dull to use, he has already begun what willbe an unpleasant shaving experience.

This final shave with a dull blade is among the more unpleasant aspectsof shaving with a razor. However, given the expense of shavingcartridges, most users are understandably reluctant to replace thecartridge prematurely.

To assist the user in determining when to replace a cartridge, the razorincludes a blade lifetime indicator 100, shown in FIG. 15A, having acounter 102 that maintains a count indicative of the extent to which theblades have been already used. The counter is in communication with boththe actuator button 22 on the handle 10, and with a cartridge detector104, mounted at the distal end of the razor head 12. A suitable counter102 can be implemented in the control logic 105.

A cartridge detector 104 can be implemented in a variety of ways. Forexample a cartridge detector 104 may include a contact configured toengage a corresponding contact on the cartridge.

Razor cartridges can include one, two, or more than two blades.Throughout this description, a single blade is referred to. It isunderstood, however, that this blade can be any blade in the cartridge,and that all the blades are subject to wear.

In operation, when the user replaces the cartridge, the cartridgedetector 104 sends a reset signal to the counter 102. Alternatively, areset signal can be generated manually, for example by the user pressinga reset button, or by the user pressing the actuator button according toa pre-determined pattern. This reset signal causes the counter 102 toreset its count.

The ability to detect the cartridge can be used for applications otherthan resetting the count. For example, the cartridge detector 104 can beused to determine whether the correct cartridge has been used, orwhether a cartridge has been inserted improperly. When connected to thecontrol logic 105, the cartridge detector 104 can cause the motor to bedisabled until the condition is corrected.

When the user shaves, the counter 102 changes the state of the count toreflect the additional wear on the blade. There are a variety of ways inwhich the counter 102 can change the state of the count.

In the implementation shown in FIG. 15A, the counter 102 changes thecount by incrementing it each time the motor is turned on. For userswhose shaving time varies little on a shave-to-shave basis, thisprovides a reasonably accurate basis for estimating blade use.

In some cases, the number of times the motor has been turned on maymisestimate the remaining lifetime of a blade. Such errors arise, forexample, when a person “borrows” one's razor to shave their legs. Thisresults in the shaving of considerable acreage with only a singleactivation of the motor.

The foregoing difficulty is overcome in an alternative implementation,shown in FIG. 15B, in which the actuator button 22 and the counter 102are in communication with a timer 106. In this case, the actuator button22 sends signals to both the control logic 105 and the timer 106.

As a result, the counter 102 maintains a count indicative of theaccumulated motor-operating time since the last cartridge replacement.

The accumulated motor-operating time provides an improved indicator ofblade wear. However, as a rule, the blade does not contact the skin atall times that the motor is operating. Thus, an estimate based on themotor's operating-time cannot help but overestimate blade wear. Inaddition, the motor switch may be inadvertently turned on, for examplewhen the razor is jostled in one's luggage. Under those circumstances,not only will the battery be drained, but the counter 102 will indicatea worn blade, even though the blade has yet to encounter a singlewhisker.

Another implementation, shown in FIG. 15C, includes a counter 102 incommunication with a stroke-detector 108. In this case, the actuatorbutton 22 signals both the stroke detector 108 and the control logic105. Thus, turning on the motor also turns on the stroke-detector 108.

The stroke-detector 108 detects contact between the blade and the skinand sends a signal to the counter 102 upon detecting such contact. Inthis way, the stroke-detector 108 provides the counter 102 with anindication that the blade is actually in use. In the implementation ofFIG. 15C, the counter 102 maintains a count indicative of theaccumulated number of strokes that the blade has endured since thecartridge was last replaced. As a result, the counter 102 ignores timeintervals during which the motor is running but the blade is notactually in use.

A variety of implementations are available for the stroke-detector 108.Some implementations rely on the change between the electricalproperties on or near the skin and electrical properties in free space.For example, the stroke-detector 108 can detect skin contact bymeasuring a change in resistance, inductance, or capacitance associatedwith contacting the skin. Other implementations rely on the differencebetween the acoustic signature of a blade vibrating on the skin and thatof a blade vibrating in free space. In these implementations, thestroke-detector 108 can include a microphone connected to a signalprocessing device configured to distinguish between the two signatures.Yet other implementations rely on changes to the motor's operatingcharacteristics when the blade touches the skin. For example, because ofthe increased load associated with skin contact, the motor's appetitefor current may increase and the motor's speed may decrease. Theseimplementations include ammeters or other current indicating devices,and/or speed sensors.

An estimate that relies on the number of strokes may nevertheless beinaccurate because not all strokes have the same length. For example, astroke down a leg may wear the blade more than the several strokesneeded to shave a moustache. The stroke-detector 108, however, cannottell the difference between strokes of different lengths.

Another implementation, shown in FIG. 15D, includes both astroke-detector 108 in communication with the actuator button 22 and atimer 106. The timer 106 is in communication with the counter 102.Again, the actuator button signals both the stroke detector 108 and thecontrol logic 105. The stroke detector 108 stops and starts the timer106 in response to detecting the beginning and end of a strokerespectively. This implementation is identical to that in FIG. 15Cexcept that the counter 102 now maintains a count indicative of theaccumulated time that the cartridge has been in contact with the skin(referred to as “stroke time”) since the last cartridge replacement.

A stroke-detector 108 in conjunction with a timer 106 as described inconnection with FIG. 15D has applications other than providinginformation indicative of blade wear. For example, the absence of astroke for an extended period of motor operation may indicate that themotor has been turned on or left on inadvertently. This may occur whenthe razor is jostled in one's luggage. Or it may occur because one hasabsent-mindedly overlooked the need to turn off the motor after shaving.

In the embodiments of FIGS. 1A-1D, the counter 102 is in communicationwith a replacement indicator 110. When the count reaches a stateindicative of a worn blade, the counter 102 sends a replacement signalto the replacement indicator 110. In response, the replacement indicator110 provides the user with a visual, audible, or tactile cue to indicatethat the blade is worn out. Exemplary cues are provided by an LED, abuzzer, or a governor that varies the motor speed, or otherwiseintroduces an irregularity, such as a stutter, into the operation of themotor.

The counter 102 includes an optional remaining-lifetime output thatprovides a remaining-life signal indicative of an estimate of theremaining life of the blade. The remaining-life estimate is obtained bycomparing the count and an expected lifetime. The remaining life signalis provided to a remaining-life indicator 112. A suitable remaining-lifeindicator 112 is a low-power display showing the expected number ofshaves remaining before the worn-out signal activates the worn-outindicator. Alternatively, the remaining lifetime estimate may be showngraphically, for example by flashing a light with a frequency indicativeof a remaining lifetime estimate, or by selectively illuminating severalLEDs according to a pre-defined pattern.

Travel Lock

In some cases, it is possible to inadvertently turn on the motor of apowered wet razor. This may occur, for example, during travel when otheritems in a toilet kit shift and press the actuator button 22. If thisoccurs, the motor will draw on the battery until the battery runs down.

To avoid this difficulty, the razor can include a lock. One such lock isa mechanical lock 200 on the actuator button 22 itself. An example of amechanical lock 200 is a sliding cover, as shown in FIG. 16A, thatcovers the actuator button 22 when the razor is put away. Other examplesof mechanical locks are associated with a holder for the razor, ratherthan with the razor itself. For example, the switch can be configured tocover the actuator button 22 when the razor is stowed in the holder.

Other locks are electronic in implementation. One example of anelectronic lock is a locking circuit 202, as shown in FIG. 16B, thatreceives a switch signal 204 from the actuator button 22 (labeled “1/0”in the figure) and an arming signal 206 from an arming circuit 208(labeled “arming-signal source” in the figure). The locking circuit 202outputs a motor control signal 210 to the control logic 105 in responseto the states of the switch signal 204 and the arming signal 206.

The arming circuit 208 is said to arm and disarm the locking circuit 202using the arming signal 206. As used herein, the locking circuit 202 isconsidered armed when pressing the actuator button 22 starts and stopsthe motor. The locking circuit 202 is considered disarmed when pressingthe actuator button 22 fails to operate the motor at all.

Arming circuits 208 and locking circuits 202 typically include digitallogic circuits that change the state of their respective outputs inresponse to state changes in their respective inputs. As such, they areconveniently implemented within the control logic 105. However, althoughdigital logic elements provide a convenient way to build such circuits,nothing precludes the use of analog or mechanical components to carryout similar functions. Examples of arming circuits 208, or portionsthereof, are described below.

One example of an arming circuit 208 includes an arming switch. In thisimplementation, the user operates the arming switch to change the stateof the arming signal 206. The user then presses the actuator button 22to start the motor. After shaving, the user again presses the actuatorbutton 22, this time to stop the motor. He then operates the armingswitch to disarm the locking circuit 202.

Alternatively, the arming circuit 208 can be configured to disarm thelocking circuit automatically upon detecting that the motor has beenturned off. In this case, the arming circuit 208 will generally includean input to receive a signal indicating that that the motor has beenturned off.

As used herein, “switch” includes buttons, levers, sliders, pads, andcombinations thereof for effecting a change in the state of a logicsignal. Switches need not be actuated by physical contact but caninstead be activated by radiant energy carried, for example, opticallyor acoustically. A switch can be directly user-operable. One example ofsuch a switch is the actuator button 22. Alternatively, the switch canbe operated by a change in the disposition of the razor, for example byreplacing a razor in its holder, or by removing and installing acartridge.

As suggested by FIG. 16B, the locking circuit 202 can be viewedabstractly as an “AND” gate. Although the locking circuit can beimplemented as an “AND” gate, any digital logic circuit with a suitabletruth table can be used to carry out the arming function of the lockingcircuit 202. For example, the locking circuit 202 can be implemented byplacing an arming switch in series with the actuator button 22.

In another implementation, the arming circuit 208 includes a timer. Theoutput of the timer causes the arming circuit 208 to initially arm thelocking circuit 202. Upon the lapse of a predetermined shaving interval,the timer causes the arming circuit 208 to disarm the locking circuit202, thereby turning off the motor. The length of the shaving intervalcorresponds to a typical shaving time. A suitable length is betweenabout five and seven minutes.

In this implementation, upon pressing the actuator button 22, the motorwill run either until the actuator button 22 is pressed again, or untilthe lapse of the shaving interval. Should the user take longer than theshaving interval to shave, the motor will turn off, in which case, theuser must press the actuator button 22 again to restart the motor andcomplete the shave. To avoid this, the arming circuit 208 can beprovided with an adaptive feedback loop that extends the default shavinginterval in response to “extensions” requested by the user.

When the arming circuit 208 includes a timer, a reset input on the timeris connected to either the output of the locking circuit 202 or to theactuator button 22. This enables the timer to reset itself in responseto a change in the state of the switch signal 204. In particular, thetimer resets itself whenever the switch signal 204 turns off the motor.This can occur when either the user presses the actuator button 22 priorto the lapse of the shaving interval, or upon the lapse of the shavinginterval.

In another implementation, the arming circuit 208 includes a decoderhaving an input connected to either the actuator button 22 or to aseparate decoder input-button. In this case, the state of the armingsignal 206, which depends on the decoder's output is controlled manuallyby the user, either by pressing the actuator button 22 according to apredefined pattern, or, in the alternative implementation, by operatingthe decoder input-button.

For example, in the case in which the decoder takes its input from theactuator button 22, the decoder may be programmed to respond to anextended press of the actuator button 22 or a rapid double-click of theactuator button 22 by causing a change to the state of the arming signal206. Alternatively, in the case in which the decoder accepts input froma separate decoder input-switch, the user need only operate the decoderinput-switch. There is no need for the user to remember how to lock andunlock the motor with the actuator button 22.

In those implementations that rely on the user to change the state ofthe arming signal 206, it is useful to provide an indicator, such as anLED, that provides the user with feedback on whether he has successfullychanged the state of the arming signal 206.

In other implementations, the arming circuit 208 relies on thedisposition of the razor to determine whether it should disarm thelocking circuit 202. For example, the arming circuit 208 may include acontact switch that detects the installation and removal of a shavingcartridge. When the cartridge is removed, the arming circuit 208 disarmsthe locking circuit 202. Alternatively, the arming circuit 208 caninclude a contact switch that detects whether or not the razor has beenstowed in its holder. In this case, when the arming circuit 208 detectsthat the razor has been stowed in its holder, it disarms the lockingcircuit 202.

In the case in which the arming circuit 208 responds to the presence ofa cartridge, a user prevents the motor from accidentally turning on byremoving the cartridge from the handle. To operate the razor normallythe user re-installs the cartridge on the handle.

In the case in which the arming circuit 208 responds to the presence ofa holder, the user prevents the motor from accidentally turning on bystowing it in its holder. The operate the razor normally, the userremoves it from its holder, which is something he would have to do inany case.

While the embodiment described herein controls the operation of a motor,the disclosed methods and devices can be used to prevent battery drainfrom inadvertent consumption of energy by any load.

Shaving Force Measurement

During the course of a shave, the user applies a force that presses theblade against the skin. The magnitude of this shaving force affects thequality of the shave. A shaving force that is too low may beinsufficient to force the whiskers into an optimum cutting position. Onethat is too high may result in excessive skin abrasion. Because of thevarying contours of the face, it is difficult for the user to maintaineven a constant shaving force, much less an optimal shaving force.

This difficulty is overcome in razors that include force-measurementcircuits 400 as shown in FIGS. 4A and 4B. The illustratedforce-measurement circuits 400 exploit the fact that in a motorizedrazor, the shaving force governs, in part, the load applied to the motor306 that drives the blade. The operating characteristics of this motor306 thus change in response to the shaving force.

The force-measurement circuit 400 shown in FIG. 17A exploits the changein the current drawn by the motor 306 in response to different loads. Asthe shaving force increases, the motor 306 draws more current inresponse. The implementation in FIG. 17A thus features a current sensor402 that senses the magnitude of the current drawn by the motor 306. Thecurrent sensor provides a force signal 408 to the control logic 105.

The force-measurement circuit shown in FIG. 17B exploits the change inmotor speed that results from different loads on the motor 306. As theshaving force increases, the motor speed decreases. The implementationshown in FIG. 17B thus features a speed sensor 410 for sensing the motorspeed. This speed sensor provides a force signal 408 to the controllogic 105.

The control logic 105 receives the force signal 408 and compares it witha nominal force signal indicative of what the force signal would beunder a known load. Typically, the known load is selected to correspondto a razor vibrating in free space, without contacting any surface.Alternatively, the control logic 105 compares the force signal 408 witha pair of nominal force signals corresponding to a razor vibrating withtwo known loads, one corresponding to a minimum shaving force andanother corresponding to a maximum shaving force.

The control logic 105 then determines whether the applied shaving forcefalls outside the band defined by the upper and lower shaving forcethresholds. If the applied shaving force falls outside the band, thecontrol logic 105 sends a correction signal 412 to an indicator 414. Theindicator 414 then transforms the correction signal 412 into anobservable signal that is observable by the user, either because it isvisible, audible, or provides some tactile stimulation.

For an acoustic observable signal, the indicator 414 can be a speakerthat provides an audible signal to the user. For an optically observablesignal, the indicator 414 can be an LED that provides a visible signalto the user. For a tactile observable signal, the motor 306 itself isused as an indicator 414. Upon detecting an incorrect shaving force, thecontrol logic 105 sends a correction signal 412 to the motor 306 tointroduce a disturbance into its normal operation. For example, thecontrol logic 105 might send a correction signal 412 that causes themotor 306 to stutter.

In all the foregoing cases, the signal for an insufficient shaving forcecan differ from that for an excessive shaving force so that the userwill know how to correct the applied shaving force.

A number of embodiments of the invention have been described.Nevertheless, it will be understood that various modifications may bemade without departing from the spirit and scope of the invention.

For example, while the razors described above include a vibration motorand provide a vibrating functionality, other types of battery-operatedfunctionality may be provided, such as heating.

Moreover, while in the embodiment described above a receiving membercontaining a window is welded into an opening in the grip tube, ifdesired the window may be molded into the grip tube, e.g., by molding atransparent membrane into the grip tube.

In some implementations, other types of battery shell attachment may beused. For example, the male and female portions of the battery shell andgrip tube may be reversed, so that the battery shell carries the maleportion and the grip tube carries the female portion. As anotherexample, the battery shell may be mounted on the grip tube using theapproach described in U.S. Ser. No. 11/115,885, filed on Apr. 27, 2005,the complete disclosure of which is incorporated herein by reference.Other mounting techniques may be used in some implementations, e.g.,latching systems that are released by a push button or other actuator.

Additionally, in some implementations the razor may be disposable, inwhich case the battery shell may be permanently welded to the grip tube,as it is not necessary or desirable that the consumer access thebattery. In disposable implementations, the blade unit is also fixedlymounted on the razor head, rather than being provided as a removablecartridge.

Other venting techniques may also be used, for example venting systemsthat employ sealing valve members rather than a microporous membrane.Such venting systems are described, for example, in U.S. Ser. No.11/115,931, filed on Apr. 27, 2005, the complete disclosure of which isincorporated herein by reference.

Some implementations include some of the features described above, butdo not include some or all of the electronic components discussedherein. For example, in some cases the electronic switch may be replacedby a mechanical switch, and the printed circuit board may be omitted.

Accordingly, other embodiments are within the scope of the followingclaims.

A number of embodiments of the invention have been described.Nevertheless, it will be understood that various modifications may bemade without departing from the spirit and scope of the invention.

For example, while the razors described above include a vibration motorand provide a vibrating functionality, other types of battery-operatedfunctionality may be provided, such as heating.

Moreover, while in the embodiment described above a receiving membercontaining a window is welded into an opening in the grip tube, ifdesired the window may be molded into the grip tube, e.g., by molding atransparent membrane into the grip tube.

In some implementations, other types of battery shell attachment may beused. For example, the male and female portions of the battery shell andgrip tube may be reversed, so that the battery shell carries the maleportion and the grip tube carries the female portion. As anotherexample, the battery shell may be mounted on the grip tube using theapproach described in U.S. Ser. No. 11/115,885, filed on Apr. 27, 2005,the complete disclosure of which is incorporated herein by reference.Other mounting techniques may be used in some implementations, e.g.,latching systems that are released by a push button or other actuator.

Additionally, in some implementations the razor may be disposable, inwhich case the battery shell may be permanently welded to the grip tube,as it is not necessary or desirable that the consumer access thebattery. In disposable implementations, the blade unit is also fixedlymounted on the razor head, rather than being provided as a removablecartridge.

Other venting techniques may also be used, for example venting systemsthat employ sealing valve members rather than a microporous membrane.Such venting systems are described, for example, in U.S. Ser. No.11/115,931, filed on Apr. 27, 2005, the complete disclosure of which isincorporated herein by reference.

Some implementations include some of the features described above, butdo not include some or all of the electronic components discussedherein. For example, in some cases the electronic switch may be replacedby a mechanical switch, and the printed circuit board may be omitted.

Accordingly, other embodiments are within the scope of the followingclaims.

1. A method of manufacturing a razor handle, comprising: forming aunitary grip tube having a closed end configured to receive a razorhead; inserting a battery and a carrier into an open opposite end of thegrip tube, the carrier having electronic components mounted thereon;sealing the open end of the grip tube; and testing the electronicfunctionality of the resulting assembly.
 2. The method of claim 1further comprising mounting a razor head on the closed end if thetesting step results in a determination that the electronics arefunctional.
 3. The method of claim 1 wherein the sealing step comprisesmounting a removable battery cover on the open end.
 4. The method ofclaim 3 wherein mounting the battery cover on the open end renders theassembly water-tight.
 5. The method of claim 2 wherein the mounting stepcomprises fixedly mounting the razor head.
 6. The method of claim 2wherein the razor head is configured to receive a disposable razorcartridge.
 7. The method of claim 1 wherein forming the unitary griptube comprises molding a grip tube preform having a window opening andwelding a window into the opening.
 8. A method of forming a plurality ofrazor products having a battery-powered functionality, the methodcomprising: forming a plurality of substantially identical razorsub-assemblies, each sub-assembly including (a) a unitary grip tubehaving a closed end configured to receive a razor head, and (b) abattery and battery-powered components disposed within the grip tube,the grip tube being sealed in a water-tight manner; and mounting a firstrazor head on the closed ends of a first sub-set of the razorsub-assemblies to form a first product, and mounting a second, differentrazor head on the closed ends of a second sub-set of the razorsub-assemblies to form a second, different product.